Dual-Cure Resin Composition for 3D Electroless Plating Substrates

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Solution Overview

Problem

Existing methods for constructing three-dimensional metal structures in shaped objects are complicated and unsuitable for forming appropriate plating films on unpolishable locations, limiting the production of high-quality three-dimensional metal structures.

Innovation Solution

A resin liquid comprising a photo-radical curable resin, thermosetting resin, and an acid catalyst, with a thermosetting resin content of 3 wt% to 60 wt%, is used to form a shaped object through shaping, photo-curing, and thermosetting processes to create a substrate suitable for electroless plating, enabling the formation of three-dimensional metal structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional methods (stereolithography with photo-curable resin) are used to form three-dimensional structures, then the shaping process is simple, but the resulting structure lacks sufficient solidity and strength to maintain complex three-dimensional metal structures

Engineering Contradiction:

Improveshaping process simplicityVSAvoidsolidity and strength of shaped object

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent uses a composite resin liquid containing both photo-curable resin and thermosetting resin. The photo-curable resin provides initial rapid solidification for simple shaping, while the thermosetting resin provides enhanced solidity and strength after thermal curing. This composite approach resolves the contradiction by combining the advantages of both material types in a single formulation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the physical and chemical parameters of the resin liquid by incorporating thermosetting resin components that require thermal treatment. The resin liquid transitions from a photo-curable state to a thermoset state through heating, fundamentally changing the material properties to achieve both ease of shaping and final structural strength.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If conventional electroless plating methods are applied to stereolithographic articles, then metal structures can be formed, but the process becomes complicated and cannot form appropriate plating films on unpolishable locations

Engineering Contradiction:

Improveability to form metal structuresVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent performs preliminary surface treatment by forming a primer layer with amino groups on the thermoset shaped object before electroless plating. This preliminary action prepares the surface for reliable metal deposition, especially on unpolishable locations, by creating a chemically active surface that promotes plate formation without requiring complex mechanical preparation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces a primer layer as an intermediary between the thermoset shaped object and the electroless plating solution. This primer layer containing amino groups acts as a mediator that facilitates the formation of metal structures, enabling reliable plating on surfaces that would otherwise be difficult to treat.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If multiple separate processes (shaping, polishing, electroless plating) are used to construct three-dimensional metal structures, then metal structures can be formed, but the production time increases significantly

Engineering Contradiction:

Improveability to form three-dimensional metal structuresVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent merges the shaping and surface preparation processes by using a composite resin liquid that can be directly shaped and then thermoset to create a surface ready for electroless plating. This eliminates the need for separate polishing and preparation steps, significantly reducing production time while maintaining the ability to form complex three-dimensional metal structures.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method allows for the production of a shaped object with sufficient solidity and strength to maintain a three-dimensional structure, facilitating the construction of a three-dimensional metal structure by electroless plating.

Implementation Method 1

a photo-radical curable resin

Methodology Applied

Scientific EffectPhoto-curing: Photopolymerisation

Implementation Method 2

a thermosetting resin; and an acid catalyst, wherein the thermosetting resin comprises a melamine crosslinking agent or a benzoguanamine crosslinking agent

Methodology Applied

Scientific EffectThermosetting: Heat Treatment

Data Source

PatentUS20260015470A1Resin liquid and method of forming shaped object

Publication Date: 2026.01.15 EEJA LTD

AI summary

Provided is a resin liquid and a method of forming a shaped object suitable for producing a shaped object including a three-dimensional metal structure. The resin liquid contains a photo-radical curable resin; a thermosetting resin; and an acid catalyst. The thermosetting resin contains a melamine crosslinking agent or a benzoguanamine crosslinking agent. The thermosetting resin content of the resin liquid is 3 wt % to 60 wt %.